Cylinder Block
- Thoroughly clean all gasket surfaces. Using a tap, clean head bolt holes. Clean oil gallery by blowing compressed air into oil filter adapter, filter by-pass, oil gallery and crankshaft oil feed holes.
- Measure cylinder bore diameter crosswise to cylinder block about 1/2" below top of bore. Repeat measurement at bottom of bore. Subtract smaller diameter from larger diameter to determine taper. Repeat measurements for each cylinder.
- Repeat measurements with measuring device rotated 90 degrees. Repeat this step for a total of 3 measurements. Cylinder out-of-round is difference between measurements. Repeat for each cylinder.
- Bore and hone cylinders for oversize pistons if taper or out-of-round exceeds specification. Move hone up and down to provide a 60-degree crosshatch pattern. DO NOT use a rigid hone or exceed 10 strokes per cylinder. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.
CRANKSHAFT JOURNAL IDENTIFICATION
| Color Code (Size) | Diameter - In. (mm) |
|---|---|
| Yellow (Standard) | 2.0955-2.0948 (53.2257-53.2079) |
| Orange (Undersize) | 2.0948-2.0941 (53.2079-53.1901) |
| Blue (Undersize) | 2.0941-2.0934 (53.1901-53.1724) |
| Red (Undersize) | 2.0855-2.0848 (52.9717-52.9539) |
CONNECTING ROD BEARING INSERT APPLICATION
| Upper Insert Size | Lower Insert Size |
|---|---|
| Yellow | Yellow |
| Yellow | Blue |
| Blue | Blue |
| Red | Red |
MAIN BEARING FITTINGS (CRANKSHAFT JOURNALS)
| Color Code (Size) | Diameter - In. (mm) | |
|---|---|---|
| Journal No. 1-6 | ||
| Yellow (Standard) | 2.5001-2.4996 (63.5025-63.4898) | |
| Orange (Undersize) | 2.4996-2.4991 (63.4898-63.4771) | |
| Blue (Undersize) | 2.4991-2.4986 (63.4771-63.4644) | |
| Green (Undersize) | 2.4986-2.4981 (63.4644-63.4517) | |
| Red (Undersize) | 2.4901-2.4896 (63.2485-63.2358) | |
| Journal No. 7 | ||
| Yellow (Standard) | 2.4995-2.4990 (63.4873-63.4746) | |
| Orange (Undersize) | 2.4990-2.4985 (63.4746-63.4619) | |
| Blue (Undersize) | 2.4985-2.4980 (63.4619-63.4492) | |
| Green (Undersize) | 2.4980-2.4975 (63.4492-63.4365) | |
| Red (Undersize) | 2.4895-2.4890 (63.2333-63.2206) | |
CRANKSHAFT BEARING INSERT APPLICATION
| Upper Insert Size | Lower Insert Size | |
|---|---|---|
| Journal No. 1-6 | ||
| Yellow | Yellow | |
| Yellow | Blue | |
| Blue | Blue | |
| Blue | Green | |
| Red | Red | |
| Journal No. 7 | ||
| Yellow | Yellow | |
| Yellow | Blue | |
| Blue | Blue | |
| Blue | Green | |
| Red | Red | |